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This Supplementary Service Manual has been prepared to introduce new service and data for the TDM850
'97. For complete service information procedures it is necessary to use this Supplementary Service Manual
together with the following manual.
TDM850 '96 SERVICE MANUAL: 4TX-AE1
© 1996 by Yamaha Motor Co., Ltd.
First Edition, October 1996 All rights
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their
qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is
assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycles has
a basic understanding of the mechanical ideas and the procedures of motorcycle repair. Repairs attempted
by anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant
changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear
in future editions of this manual where applicable.
Designs and specifications are subject to change without notice.
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person inspecting or repairing the motor-
A CAUTION indicates special precautions that must be taken to avoid damage to
A NOTE provides key information to make procedures easier or clearer.
HOW TO USE THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See "Illustrated symbols".)
1 st title (T): This si the title of the chapter with its symbol in the upper right corner of each page.
2nd title (2) : This title indicates the section of the chapter and only appears on the tirst page of each section .
It is located in the upper left corner of the page.
3rd title (3): This title indicates a sub-section that is followed by step-by-step procedures accompanied by
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal
and disassembly section.
1 . An easy-to-see exploded diagram is provided for removal and disassembly jobs.
2. Numbers (5) are given in the order of the jobs in the exploded diagram. A number that is enclosed by
circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks©. The
meanings of the symbol marks are given on the next page.
4. A job instruction chart (?) accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements® are given in addition to the
exploded diagram and the job instruction chart.
me /Part name
let (right) removal
Remove the parts in the order below.
Refer to "ENGINE OIL REPLACEMENT
in CHAPTER 3.
Loosen the bolts in a cnssc.oss pattern.
For installation, reverse the removal
i boss nut©
he clutch boss nut © while holding the
1 §^y Universal clutch holder:
.....,..:. . ■....■
i surface plate and feeler gauge (T).
■ Free length (clutch spring) (a)
/M Free length (clutch spring):
Q Q Q
Illustrated symbols © to (9) are printed on top
right of each page and indicate the subject of each
(T) General information
(3) Periodic inspections and adjustments
(5) Cooling system
Illustrated symbols © to © are used to identify
the specifications appearing in the text.
@ Can be serviced with engine mounted
@ Filling fluid
@) Special tool
@ Wear limit, clearance
@ Engine speed
<xh a V, A
Illustrated symbols ® to @) in the exploded dia-
grams indicate the types of lubricants and lubrica-
@ Apply engine oil
@) Apply gear oil
@ Apply molybdenum disulfide oil
@ Apply wheel bearing grease
@) Apply lightweight lithium soap base grease
@) Apply molybdenum disulfide grease
Illustrated symbols @ to @) in the exploded dia-
grams indicate where to apply a locking agent ®
and when to install new parts @).
@ Apply locking agent (LOCTITE®)
GENERAL INFORMATION 1
MOTORCYCLE IDENTIFICATION 1
VEHICLE IDENTIFICATION NUMBER 1
MODEL LABEL 1
GENERAL SPECIFICATIONS 2
MAINTENANCE SPECIFICATIONS 3
FUEL LEVEL ADJUSTMENT 5
TDM850 '97 WIRING DIAGRAM
/ @^=- ;==::::: ^ ~x/r
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number © is stamped
into the right side of the steering head.
The model label © is affixed to the frame.
This information will be needed to order spare
Minimum ground clearance
Minimum turning radius
Radiator capacity (including all routes)
*ln Austria and Switzerland only Bridgestone
tires are equipped on this mode.
Main air jet
Pilot air jet 1
Pilot air jet 2
Valve seat size
Starter jet 1
Starter jet 2
Throttle valve size
15.8 ~ 16.8 mm
Engine idle speed
1,100 ~ 1,200 r/min
36.0 ~ 38.7 kPa (270 ~ 290 mmHg)
Part to be tightened
Part to be tightened
Rear brake caliper and brake hose joint
Ignition timing (B.T.D.C.)
10° at 1,150 r/min
TPS and electrical type
No load regulated voltage
Semi conductor-short circuit type
14.1 ~ 14.9 V
FUEL LEVEL ADJUSTMENT
• Fuel level®
15.8 ~ 16.8 mm
(below the MIKUNI mark)
Out of specification -► Adjust.
Adjust the float level by slightly bending the float
Fuel level measurement and adjustment
• Place the motorcycle on a level surface.
• Use a garage jack under the engine to ensure
that the carburetors are positioned vertically.
• Connect the fuel level gauge (2) to the drain
Fuel level gauge:
•Loosen the drain screw.
•Hold the gauge vertically next to the MIKUNI
• Measure the fuel level (a) with the gauge.
TDM850 '97 WIRING DIAGRAM (EXCEPT FOR CH, A)
A.C. magneto/pickup coil
Starting circuit cut-off relay
Gear position switch
T.P.S. (throttle position sensor)
Water temperature meter
Neutral indicator light
High beam indicator light
Turn indicator ligh
Rear flasher light
Front flasher light
Left handlebar switch
Radiator fan fuse
Rear brake switch
Signal system fuse
Right handlebar switch
Front brake switch
Engine stop switch
. . Black
. . Blue
. . Yellow
. . Brown/White
. . Brown
. . Light green
. . Black/Blue
. . Green/ Red
. . Chocolate
. . Orange
.. Black/ Red
. . Green/White
. . Dark green
. . Black/White
. . Green/Yellow
. . Green
. . Sky blue
. . Black/Yellow
. . Blue/Black
. Red /Yellow
. . Gray
. . White
. . Brown/Blue
. . Blue/Red